Fully Functional Universal Testing System EF02

     I. Product Background

FCT That is Functional testing of circuit boards is an essential step in the electronics manufacturing process. Traditionally, this type of testing is performed manually: operators connect various benchtop instruments—such as power supplies, signal generators, oscilloscopes, and multimeters—to the circuit board under test. They then manually operate each instrument step by step, meticulously measuring individual electrical parameters one at a time. Finally, human operators interpret the results, determining whether the board passes or fails, and manually document the test data. However, this manual testing approach not only slows down the process and reduces efficiency but also introduces significant risks due to human error, such as misoperations or incorrect judgments. As a result, the reliability and consistency of the testing are compromised, making it difficult to ensure the final product meets quality standards.

With the rapid advancement of computer-based electronic testing technology, automated functional test equipment has seen significant growth. These automated systems are centered around a computer—typically an industrial PC or standard PC—and leverage various bus technologies such as GPIB, PCI, VXI, PXI, and USB to interconnect individual benchtop instruments or instrument modules. Using specialized software running on the host computer, the system can automatically control each instrument module, execute predefined test procedures, and apply precise test parameters. This allows the equipment to perform comprehensive functional tests on the circuit boards (or entire devices) under test, automatically evaluate the results, and save all test outcomes directly onto the hard drive for easy access, analysis, and statistical reporting. Such capabilities streamline production process management and control, making it easier to monitor and optimize manufacturing workflows.

The adoption of automated functional testing equipment not only enhances testing efficiency but also ensures greater consistency and reliability in test results, thereby guaranteeing the quality of the electronic products being manufactured. At the same time, it significantly reduces the technical expertise required from testing personnel, helping companies cut labor costs. Moreover, implementing automated testing equipment can effectively boost a company’s corporate image, fostering customer trust in an increasingly competitive market. As a result, automated functional testing equipment is gaining popularity among more and more electronics manufacturers and enterprises.

As electronic manufacturers—particularly in the small appliance industry, such as air conditioners, refrigerators, and mobile phones—continue to ramp up their daily production output, the demand for FCT equipment is growing steadily. However, large-scale automated functional testing systems typically require connection to a variety of peripherals, like multimeters, oscilloscopes, and more. This dependency on external devices not only makes the automated test equipment bulky and expensive but also slows down the testing process, as measurements often rely on these peripheral instruments. As a result, such systems are less ideal for smaller and medium-sized enterprises that are price-sensitive and demand faster throughput, as well as for applications that call for compact, space-efficient equipment.

In summary, there is a need for a miniaturized, cost-effective universal function testing system that supports touch-screen operation and can be controlled and displayed via devices such as pads and laptops. Additionally, the system should easily accommodate external peripherals like oscilloscopes, multimeters, and programmable power supplies, offering full-featured functionality.

Two , Technical indicators

1. Technical Specifications for Component Measurement Board

1) Voltage Measurement: 16-bit high-precision voltage bus measurement

A: Measurement Mode: Bus measurement, using the measurement/channel switching board to toggle between acquisition channels.

B: Voltage Acquisition (Isolated Acquisition)

Voltage range: -400 to +400V ±0.1% The range of the measured voltage is determined by the measurement/channel switching board.

2) Resistance Measurement

Measurement range: 5Ω to 5MΩ ±1%

3) Capacitance Measurement

Measurement range: 1 nF - 1000 µF ±5%

4) Diode Measurement

Measurement range: Measure the forward and reverse characteristics of the PN junction.

5) Inductance Measurement

Measurement range: 10 µH – 100 mH ±1%

6) Current Measurement (Common-Ground Measurement)

A. Number of channels: 4 lanes

B. Voltage Resistance: 220V

C. Current Range: DC ±2A ±1%; AC Maximum ±2A ±1%;

2. Technical Specifications for the Measurement/Channel Switching Board

1) Channel Count: 32 channels per block, which can be used either as channel expansion for the component measurement board or as standalone acquisition channels. Each system can be configured with up to 16 switch boards.

2) Voltage Acquisition (Isolated Acquisition)

Voltage range: Standard configuration: -200 to +200V

-0.5 to +0.5V, accuracy 3%; -200 to -0.5V and 0.5 to 200V, accuracy 1%.

Optional: -400~+400V

-0.5 to +0.5V, accuracy 3%; -400 to -0.5V and 0.5 to 400V, accuracy 1%

3) Frequency Acquisition

Frequency range: 2 Hz to 100 kHz Accuracy: 2%

4) Waveform Analysis

A. Frequency range: 1 Hz - 1 kHz ±2%

B. Voltage amplitude: -200 to +200 V ±1%

The main functions of waveform analysis include: maximum value, minimum value, peak-to-peak amplitude, duty cycle, and phase difference.

3. Technical Specifications of the Programmable Power Supply Board

1) Channels: 2 channels, capable of common-ground output in either constant-current (current-limit mode) or constant-voltage.

2) Voltage range: 1.5–28V, step size 0.01V, accuracy 1%

Standard configuration: Powered by internal power supply; when using the internal power supply, the maximum output voltage is 1V less than the supply voltage of the programmable power board. Optional external power supply option—when the external power source exceeds 28V, the output voltage ranges from 1.5V to 28V.

3) Current range: Constant current from 100 mA to 1.5 A, with an accuracy of ±1% + 1 mA; the current limit can be set manually.

4. Technical Specifications for the IO Input/Output Board

1) Channels: 16 output channels (every 8 channels form a group, totaling two groups; these groups are not common-ground with the system, but share a common ground internally within the board.)

16-channel digital input signals (high-level compatible with 1.8–30V voltage, low-level below 0.5V).

2) Voltage and Current: Maximum input voltage 30V

Output maximum voltage of 30V (determined by the supply voltage; internal power supply of 5V is optional), with a current limit of 50 mA.

5. Technical Specifications for the Digital Output Board

1) Channels: 24 channels (normally open and normally closed)

2) Rated current: 2A

3) Withstand Voltage: 200V

6. Technical specifications for the high-current load board:

1) Channels: 16

2) Rated current: 5A

7. Technical specifications for infrared and four-phase eight-step drive technology:

1) Infrared is used to simulate a remote control, capable of learning 50 remote control commands—both sending and receiving. It can also independently send or receive remote control commands via host computer software.

2) Four-phase eight-step method for detecting stepper motors:

A. Amplitude Measurement: Accuracy ±1% | Range: 0–60V | Resolution: 5mV

B. Detection Frequency: Accuracy ±2% Range: 1 Hz–200 Hz (accuracy decreases above 200 Hz)

C. Phase Difference Detection: Accuracy of 2°, Range: 1 Hz – 200 Hz (accuracy decreases beyond this range)

D. DC Voltage Measurement: Accuracy ±2%, Range: 0 to ±60V

3) IIC Communication

Read and write IIC data, with a maximum single transmission/reception of 128 bytes. Each board has one channel.

8. Technical Specifications of the Signal Source Board:

1) Channel count: 2 channels, non-common ground outputs; the negative terminals of the two output channels are at the same potential.

2) Output signal types: DC voltage, PWM square wave, triangular wave, sine wave

3) Output voltage: -15V to 15V, with 2% accuracy

4) Output frequency range: 0.1–10 kHz, with an accuracy of 1%

5) Duty Cycle: 1%–99%, Resolution: 1%

9. Technical Specifications for Active Load Board

1) Programmable voltage output: DC 2V to 6V, with an accuracy of 0.5%. Current limiting ranges from 0 to 300 µA, 300 µA to 30 mA, and 30 mA to 3 A, each with an accuracy of 5%.

2) Programmable load output: Constant voltage from 1V to 8V with 1% accuracy

Constant current: 0–300 µA, 300 µA–30 mA, 30 mA–3 A; Accuracy: 0.5%

Constant resistance ranging from 100 ohms to 2080 ohms, with a resolution of 1.93 ohms and an accuracy of 2%.

2080 EUR to 10,720 EUR, with a resolution of 9.96 EUR and an accuracy of 2%.

10,720 euros to 208,030 euros, with a resolution of 193.3 euros and an accuracy of 2%.

208,030 EUR to 1,072,020 EUR, with a resolution of 996 EUR and an accuracy of 2%.

10,720.20 EUR to 20,803,067 EUR, with a resolution of 19,329 EUR and an accuracy of 2%.

20,803,067 EUR to 17,202,000 EUR, with a resolution of 99,609 EUR and an accuracy of 2%.

3. Product Highlights

1. Each functional module is equipped with an STM32 chip, ensuring fast operation and stable testing.

2. It uses a pad or laptop as the display screen and runs host computer software, offering a large display and simple operation. Powered by the Windows system, it aligns with the familiar operating habits of most users while enabling all standard Windows functions—making it highly versatile and powerful. The host computer software operates seamlessly under Windows, allowing for convenient modification and expansion of its features.

3. The software is shared with the large-scale FCT testing system and boasts powerful functionality—enabling convenient editing of test files, as well as features like statistical analysis and export of test result files. Additionally, the unified software platform simplifies maintenance tasks.

4. It shares software with the large FCT system and can also connect standard instrumentation devices such as serial ports and USB interfaces, working seamlessly with EF02 hardware—making device expansion incredibly convenient.

5. Utilizes a table-based programming interface (similar to the format of inspection process documents used on-site), making it easy to create test steps and allowing users to freely adjust the sequence of test steps, as well as flexibly combine test timing and logical relationships.

6. Universal Design: During hardware design, we’ve carefully considered versatility. As long as the hardware components fall within the functional specifications of the tester, customers can easily swap out different products under test—simply by replacing the corresponding test fixtures and loading the appropriate test files—and then proceed with testing.

7. Equipped with automatic full-function testing and manual single-step test selection capabilities, as well as step-by-step loop testing functionality, making it easy for customer engineers to debug the board under test.

8. When a specified defect in the circuit board under test—such as a power short circuit—occurs, the system automatically stops the test to protect both the board being tested and the testing system, preventing the fault from escalating.

9. A single software suite can simultaneously control multiple hardware systems, enabling parallel testing and significantly boosting test efficiency.

10. Utilizing database management facilitates easy data access and statistical analysis. All test data and results are stored in the database, which also includes built-in software for analyzing test results. This software allows convenient access to the database, enabling seamless statistical evaluation of the test outcomes.

11. Universal MES interface functionality for seamless data import into the MES system. By leveraging a unified MES interface, customers only need to perform simple setup on the MES side—specifically, configuring the stored procedure that receives data—to effortlessly transmit test results directly into their own MES systems, enabling centralized and efficient data management.

4. Target Customer Base

1. This service is available to manufacturers and processors of jigs and fixtures. When accepting orders, some customers may have simple functional testing requirements—these board cards can be sold directly to them.

2. Compare smaller circuit board manufacturers that produce relatively high volumes. Smaller boards typically require simpler functionality tests, while higher-volume production demands more extensive test equipment—and thus places greater emphasis on cost-effectiveness. These types of customers can benefit from purchasing multiple units at lower prices.

3. No high voltage or high-power supply is required; aside from serial communication, there are no other types of communication interfaces. It can test voltage, current, resistance, and frequency. Most circuit boards of this type are suitable for testing.

4. For functional tests that don’t involve using external instruments like multimeters or oscilloscopes, the EF02 structure can be used as an alternative for testing purposes.